Particle separator systems and processes for improving food safety

ABSTRACT

The disclosure provides a particle separator for removing aerosolized particles from exhaust emissions from a preconditioner or other apparatus. The separator comprises an enclosure with at least two baffles linearly spaced from one another therein. At least two baffles prevent the exhaust from linearly flowing directly from an inlet through the separator to an outlet. Each baffle is positioned at an angle relative to the linear flow of exhaust into the separator and a distance from an inner surface of the separator. This places a leading edge within the exhaust flow to redirect a portion of the flow, thereby promoting impact of particles on a portion of the inner surface of the separator, while also providing a surface that collects particles in the flow that impact the baffle surface. The separator and baffle surfaces can be cleaned through an access. The separator can be box- or tube-shaped or other configuration.

FIELD OF THE INVENTION

The invention relates generally to the field of exhaust vent management systems for food and other processing or industrial machinery that produce dry or steam exhaust emissions commingled with any size of particulate matter. More specifically, the invention is concerned with removing particulate matter from exhaust vents of extruders, such as those operating relative to a preconditioner, whereby a device removes particulates from steam exiting a preconditioner to reduce contamination and other problems caused by exhausting damp particulate matter into the environment of the extrusion operation. The invention is also concerned with improving food production processes and the end product thereof.

BACKGROUND OF THE INVENTION

A preconditioner is an apparatus widely used in combination with an extruder or feed pellet mill to manufacture food products, such as, for example, flakes or pellets for cereals and snacks, pet food, pet treats, and fish feed. A preconditioner heats, hydrates, and mixes the dry raw materials (e.g., protein, fat, starch, etc.) before extrusion or milling and automatically doses the pre-treated product into the processing apparatus, e.g., extruder or feed pellet mill A preconditioner can also be used to partially cook the starting ingredients prior to extrusion. For example, starting ingredients typically have a relatively high percentage of powdered or ground ingredients, e.g., flour-like material such as corn or wheat, that require blending with water and/or treatment with steam in the preconditioner to facilitate downstream extrusion or milling The use of a preconditioner is advantageous in preparing products comprised of farinaceous material, such as pet food or treats, containing a relatively large percentage of flour and other ground ingredients.

Generally, a preconditioner includes injection ports for introducing steam and/or water into the chamber of the preconditioner to be mixed with other starting ingredients with mixing paddles, counter-rotating screws, or other mixing devices during processing in the preconditioner. The steam may be pressurized to about 30-80 psi prior to injection into the preconditioner. The combination of energy (thermal and mechanical) in the preconditioner can be used to partially cook ingredients and even to pregelatinize starch in the preconditioner.

The pressurized steam must condense in the preconditioner to be effective. Typically, a portion of the pressurized steam exits the preconditioner as “blow out” through a vent that exhausts a gaseous mixture to prevent the buildup of undesired pressure in the preconditioner. The gaseous mixture can include steam, air, and particulate matter comprising the starting ingredients that become aerosolized by and with the steam.

The manufacturing operations for pet and human food includes blending of raw material (dry and wet) prior to heat treatment. In general, most food formulations include grains, e.g., corn, wheat, and their products such as gluten. Some of these ingredients may be contaminated with or contain naturally-occurring pathogens, bacteria, toxins and/or mold that are known to cause illnesses. For example, meat meal and animal proteins can be contaminated with Salmonella, Staphylococcus, and Coliform bacteria such as E. coli. Cereal grains (corn, wheat, and their products), legumes (peanuts), and oilseeds may be contaminated with fungi or molds that product toxins, such as aflatoxin produced by Aspergillus.

One function of an extruder is to quickly cook and pasteurize the food or feed at temperatures high enough to kill a majority of the microbes and destroy toxins present in the starting ingredients. Preconditioning the starting ingredients can start the kill process for microbes and/or destroy toxins. However, the introduction of pressured steam and/or water into the wet and dry starting ingredients can create blow off in the form of preconditioner exhaust. This exhaust can contain contaminated starting materials and dust that are hosts for pathogens that can survive for up to 300 days. This exhaust is typically not exposed to a high temperature kill step to destroy toxins or to kill microorganisms.

The handling of the preconditioner exhaust is a problem throughout the pet and human food processing industry. If the exhaust is untreated, which has been a common approach in the industry, then it will be dispersed throughout the production facility and settle on and coat the surfaces of the production machines, pipes, floor and other exposed surfaces in the facility. The commingling of steam with proteinaceous particulate matter and other starting ingredients provides ideal conditions to support microbial growth as those microbe(s) and their by-products are exhausted with the steam into the processing facility and deposits on surfaces. The moisture creates conditions that promote the growth of microbes that are dispersed with the exhaust, as well as other microbes, such as fungus, mold, or bacteria, that are present in the processing environment. Any toxins, e.g., aflatoxin, that may be present in the starting ingredients may also be aerosolized by the exhaust and disbursed throughout the processing environment.

The spread of microbes and toxins by the exhaust poses a food safety concern because the finished product, which is produced in the processing environment, can become contaminated through exposure to the microbes and/or toxins.

Other concerns include workplace safety. Plant operators can become ill through exposure to microbes and/or toxins exhausted into the processing environment. Additionally, the moist coating is slippery and creates a hazardous work environment that must be constantly maintained in order to avoid workplace injury. Finally, the moist coating can also cause corrosion of the processing machines and other surfaces.

Management systems for preconditioner exhaust have been developed for processing or collecting vent exhaust. These systems include collection bags, fan suction with centrifugal separators, cooling systems combined with increased diameter vent pipes, confined space such as a closed-off room to collect exhaust, and water scrubbers. All of these systems have significant limitations for a variety of reasons that include high cost or ineffective or inefficient systems. For example, baghouse collectors have been used unsuccessfully with vent stacks to filter particulate matter from the steam using a fabric filter. The particulate matter and steam form a mud-like material that clogs the filter and renders the collector ineffective for managing vent exhaust.

An alternative system implementing wet centrifugal collectors (RotoClone) centrifugally separates the exhaust into water and particulate matter and then separately collects the water and particulate matter. This type of collector introduces exhaust into a chamber having a fan or impeller that separates the exhaust into water disposed of with a drain and particulate matter disposed of in a separate chute. This collector system is inefficient because the disposal drain and chute routinely clog and require constant maintenance to prevent back up of the collector.

A further approach to managing vent exhaust uses a cooling system that operates as a condenser with a large-diameter pipe vent. When the steam cools, water along with particulate matter condenses onto the vent pipes and then drains back into the preconditioner. This system fails to treat all of the exhaust because a significant amount of steam with particulate matter does not condense and vents into the processing machinery environment. This system also requires additional utilities to operate and support the cooling system.

Another solution vents exhaust directly into a confined space such as a room. This produces similar problems as direct venting exhaust into a production facility.

Water scrubbers have been explored as a possible alternative solution for managing vent exhaust. In one type of water scrubber, water nozzles spray water into the exhaust flowing in the vent to disrupt the flow of steam and particulate matter. This causes water and particulate matter to collect in the vent pipe and then return to the preconditioner and alter the composition of the preconditioned material. Water scrubbers also require additional utilities to manage water flow to the scrubber.

Outside the field of food processing equipment, other systems have been used to remove ultra-fine particles and water droplets present in a gas stream flowing in an industrial process. For example, some centrifugal collectors use cyclonic action to separate dust particles or water droplets from the gas stream. In a typical cyclone, the dust gas stream enters a funnel-like, cyclonic container at an angle and is spun rapidly. The centrifugal force created by the circular flow directs the dust particles toward the wall of the cyclone. After striking the wall, these particles fall into a hopper located underneath the collector. The most common types of centrifugal collectors in use today are: single-cyclone separators, multiple-cyclone separators, and secondary-air-flow separators. These systems are used for removing ultra-fine particulate matter from dry gas streams.

Impact separators are another type of system used to remove ultra-fine particles and water droplets present in a gas stream flowing in an industrial process. Impact separators use fixed plates or L-shaped or U-shaped bends in tubing that causes the conveying gas stream to make a sudden change of direction. Particles and water droplets do not follow the gas stream because either inertia carries them into a surface of the separator or the gas stream becomes turbulent and slows in a dead air space. In either case, the particles and/or water fall out of the flowing gas stream. Impact separators are typically used as precleaners for industrial operations and are intended for use in removing ultra-fine, but not course, particulate matter from dry gas streams. Impact separators remove particles with high inertia or low drag from the gas stream, but low inertia or high drag particles remain in the gas stream line and continue to flow with the gas which must be passed through a filter(s). This system would not work effectively with a water saturated exhaust vented from a food processing operation.

The subject matter disclosed herein provides a particle separator apparatus, and methods of use thereof, that: (1) cleans exhaust steam or gas by removing at least 80% or more particulate matter flowing in the exhaust; (2) is a low cost alternative to more expensive vent management systems; (3) is easy to clean and does not clog readily during day-to-day use; (4) provides an easy fit with existing vent stacks used with food processing equipment; (5) reduces sanitation costs by significantly reducing, if not eliminating, the settlement of blow off on surfaces in the process operation environment, and potential contamination by microbes and their by-products (e.g., toxins) by removing uncooked meat particulates and other ingredients, as well as microbes and their by-products (e.g., toxins) from the exhaust; (6) reduces workplace hazards by significantly reducing or eliminating blow off of wet exhaust into the processing operation environment; (7) reduces the corrosion of processing equipment, e.g., extruders, pipes, etc.; (8) reduces risk of contamination of food products that would result from microbes, such as Salmonella, and their by-products, such as toxins, that settle on intermediate or finished food products; (9) reduces energy use by the processing equipment by increasing the retention time of heat (steam) in the preconditioner by restricting steam flow in the exhaust; (10) increases the quality of finished product by reducing variations in processing temperatures in the preconditioner; (11) has no moving parts or requirements for utilities (e.g., electricity, gas, plumbing) which reduces risk of system failure to machine design and risk in the production flow; and (12) is self-cleaning.

The subject matter disclosed herein improves upon or overcomes one or more of the shortcomings of solutions proposed for managing vent exhaust from food processing machines.

BRIEF DESCRIPTION OF THE FIGURES

Additional aspects, features and advantages of the invention, as to its structure, assembly and use, will be understood and become more readily apparent when the invention is considered in light of the following brief description of the figures made in conjunction with the accompanying drawings, wherein:

FIG. 1 shows a front perspective view of the particle separator of the present invention with its door open.

FIGS. 2a and 2b show a front plan view of the particle separator shown in FIG. 1 (without the door), while FIG. 2c shows a cutaway view of the particle separator of FIG. 1.

FIG. 3 shows a side plan view of the particle separator shown in FIG. 1.

FIG. 4 shows a top view of the particle separator in FIG. 1.

FIG. 5 shows a bottom view of the particle separator in FIG. 1.

FIG. 6 shows a top view of a baffle used with the particle separator shown in FIG. 1.

FIG. 7 shows a perspective view of an alternative embodiment of the particle separator.

FIG. 8 shows a cutaway view of an alternative embodiment of the particle separator.

FIG. 9 shows a top view of a baffle used with the particle separator shown in FIG. 7.

FIGS. 10a, 10b, and 10c show side sectional views of the particle separator shown in FIG. 7.

FIG. 11a shows an airflow schematic in a cross-sectional view of the particle separator shown in FIG. 1.

FIG. 11b shows a schematic of the density of particles in exhaust flowing through the particle separator, as well as the general location of particle deposition on the surfaces of the baffles and inner walls of the particle separator.

FIG. 11c shows a schematic depicting subchambers of the particle separator.

FIG. 12 shows an airflow schematic in a cross-sectional view of an alternative embodiment of the particle separator.

BRIEF DESCRIPTION OF THE INVENTION

Illustrative and alternative embodiments of a particle separator 100 for cleaning vent exhaust from food processing operations are described in detail with reference being made to the figures of this application. Although similar aspects of embodiments are featured throughout this disclosure and are readily apparent, these similarities may be repeated within the context of the various embodiments of the invention.

The term “particle” or “particles” means any wet or dry piece of matter that can travel within a gas flow and can range in size from a nanoparticle to a macroparticle.

The term “exhaust” means any combination of gas, steam and/or particles that exit and/or flow within a preconditioner, extruder or other food processing apparatus, or other apparatus or equipment having a gas flow operation.

The particle separator 100 provides technology for removing aerosolized particulate matter from exhaust produced in a preconditioner for an extruder (Wenger, ExtruTech, Ever Extrude, Horizon) or other operation during food production. The particle separator 100 is an optimized, high performance vent management system that separates particles from a flow of exhaust by directing uncooked or partially-cooked particles into an array of linearly-spaced baffles that divide and redirect a flow of exhaust around the baffles. The capacity to handle a high volumetric flow rate, e.g., about 120-220 CFM or higher, from standard exhaust tubes, e.g., 6-, 8-, and 10-inch tubes, used with food processing equipment, when combined with ease of use and effectiveness, makes the particle separator 100 a practical solution to the problems that exist with other technologies used to scrub vent exhaust. No significant backpressure, if any, is created by the particle separator 100 during operation.

The particle separator 100 incorporates an array of baffles to divide and redirect the entire flow of particle-laden exhaust while removing particles therefrom. In the particle separator 100 shown in FIGS. 11a, 11b , and 12, which defines an enclosed space 104 having inlet 110 and outlet 120 openings, particle-laden exhaust is fed by a vent through the inlet 110 and directed into at least two linearly-spaced baffles 140 a, 140 b. The particle-laden exhaust encounters a first baffle 140 a having a leading edge 146 that divides the flow of exhaust and redirects a portion of the flow into and along an upstream surface 142 of the baffle 140 a, while the other portion of exhaust flows linearly past the first baffle 140 a. The first baffle 140 a provides an intercept surface—upstream surface 142 - with which particles impact as a result of inertia and collect during operation of the particle separator 100. The exhaust becomes turbulent as it is redirected by the first baffle 140 a into an inner surface 102 of the particle separator 100 and then either recirculates with the flow of exhaust upstream from the first baffle 140 a or circulates within lateral spaces of the particle separator 100 and flows downstream from the first baffle 140 a.

Referring now to FIGS. 11a, 11b , and 12, the particle-laden exhaust, which flows linearly past the first baffle 140 a without being redirected by it, encounters a second baffle 140 b downstream from the first baffle 140 a. The second baffle 140 b provides an intercept surface—upstream surface 142—into which particles impact due to inertia and collect. The second baffle 140 b also redirects the flow of exhaust into an inner surface 102 of the particle separator 100. The exhaust becomes turbulent as it is redirected by the second baffle 140 b and then either flows downstream from the second baffle or recirculates with the flow of exhaust upstream from the second baffle 140 b.

Referring now to FIGS. 11a and 11 b, the first baffle 140 a and the second baffle 140 b prevent linear flow of exhaust from the inlet 110 to the outlet 120 by dividing and redirecting the entire flow of particle-laden exhaust before passage of the exhaust through and out of the outlet 120 of the particle separator 100. One or more baffles, e.g., third baffle 140 c (shown in FIGS. 11a and 11b ), may be provided downstream from the first baffle 140 a and second baffle 140 b in the particle separator 100. The additional baffle(s) also function to redirect exhaust circulating within the particle separator 100, as well as collect particles that deposit on the surfaces of the baffle(s) and inner surface 102 of the particle separator 100. There is no limitation on the size of particle—large or small—that the particle separator 100 can remove from exhaust before the exhaust exits from the particle separator 100.

FIG. 2a shows the baffles linearly spaced from one another at a distance X. Distance X is configured to prevent the particle-laden exhaust from simply being slightly diverted by the baffles while flowing through the particle separator 100. Rather, distance X is configured so that the baffles divide and redirect the entire flow of exhaust entering through the inlet 110, thereby promoting the impact of particles on the upstream surface 142 of at least one of the baffles 140 a, 140 b, 140 c. In an embodiment, the distance X is less than the diameter of the tube 112 or the width of the opening of an inlet into the particle separator 100.

The volumetric flow rate (about 120-220 CFM) of exhaust entering the particle separator 100 can also play a role in determining distance X. In an exemplary embodiment, the area of the opening (width W by height H, see FIG. 2c ) between the leading edges 146 of two sequential baffles 140 a, 140 b can be about 65-100% of the cross-sectional area of the inlet 110 receiving exhaust from a preconditioner or other equipment from which the exhaust is being vented. In embodiments where the area of the opening between the leading edges 146 of two sequential baffles 140 a, 140 b is restricted to less than 100% of the cross-sectional area of the inlet 110 (which can be determined using diameter N, see FIG. 2c ), then the Venturi effect will cause the flow of exhaust including any particles to accelerate as it passes through the opening between the leading edges 146 of two sequential baffles 140 a, 140 b.

In various embodiments, the upstream and downstream surfaces 142, 144 of the baffles and, optionally, the inner surface 102 of the particle separator 100, may have a coating. For example, a rough coating may be applied to the upstream and/or downstream surfaces of baffles 142, 144 and, optionally, the inner surface 102. A purpose of the rough coating (Stove Bright 1PC-653-Series, 1IP-653-Series—Forest) will be to capture and hold particulate matter on the surfaces 142, 144 of the baffles and, optionally, the inner surface 102. Alternatively, a slick coating (Du Pont Silver stone Teflon ((polytetraflouroethylene (PTFE) or fluorinated ethylene propylene (FEP)) may be applied to the upstream and/or downstream surfaces 142, 144 of the baffles and, optionally, the inner surface 102. The purpose of the slick coating in combination with the angle α of a baffle promotes water and particles to collect on the surfaces 142, 144, 102 and then slide off those surfaces and fall back into the preconditioner. Of course, the surfaces, e.g., upstream 142, downstream 144, and inner 102, may all have the same type of coating or a combination of different coatings. By way of a non-limiting example, the upstream surface 142 may have a rough coating, while the downstream surface 144 and inner surface 102 may have a slick coating.

In various embodiments, the upstream and downstream surfaces 142, 144 of the baffles, as well as, optionally, the inner surface 102 of the particle separator 100, may have channels etched into those surfaces or defined by raised portions of material affixed to the surfaces to collect and direct moisture and particles to flow off of the surfaces 142, 144, 102 and back into the preconditioner or into a drain or other communication.

In embodiments, the leading edge 146 can be linear as shown in FIGS. 1, 4-5, linear with one or more cutaways as shown in FIG. 8, curvilinear, v-shaped, or other linear or curvilinear edge, or combination thereof. In any of the aforementioned embodiments, the leading edge can also be notched by linear and/or curvilinear cutouts. The leading edge may include any one or more extensions in any geometric shape that project further into the flow of exhaust to create additional turbulence, as well as provide an impact surface to remove particles from the exhaust.

FIGS. 1-2 show a particle separator 100 with an open door 130 providing access to the enclosed space 104 and baffles. The particle separator 100 has an inlet 110 and an outlet 120. The inlet 110 provides an opening for particle-laden exhaust to be fed into the particle separator 100 from a preconditioner vent or other source of exhaust. The inlet 100 may include a tube 112 with a length sufficient enough to be attached by bolts or other fasteners with an optional flange that may be sealed to a vent pipe on its upstream end and the particle separator 100 on its downstream end. The cross-sectional size and shape of the tube 112 is not critical so long as it fits the vent pipe and can be secured thereto. The outlet 120 provides an opening for exhaust to exit the particle separator 100 after passing by the array of baffles. The outlet 120 includes a tube 122 to direct the exhaust exiting the particle separator 100. The cross-sectional shape, size and length of the outlet 120 is not critical, but can be configured in such a manner to connect with additional pipes and/or one or more downstream particle separator(s), stack(s), filter(s), water scrubber(s), electrostatic precipitator(s), or other apparatus.

FIGS. 1-6 show the particle separator 100 generally as a rectangular-shaped box with a horizontal cross-section that is generally square and a vertical cross-section that is generally rectangular. In alternative embodiments, the particle separator 100 can be a square-shaped box, a tube 200 such as shown in FIGS. 7-10 b, elbow or bend (e.g., tube with a bend of no more than 90 degrees), or other 3-dimensional shape. FIGS. 1-6 show the particle separator 100 having a bottom with a tapered surface. In alternative configurations, the bottom and/or the top surface of the particle separator 100 may be flat or tapered. In further configurations, the particle separator 100 does not have a top or bottom surface, such as the tube shaped embodiment 200 shown in FIGS. 7-10 b.

FIGS. 1-2 show an array of baffles spaced linearly from one another within the particle separator 100 between the inlet 110 and the outlet 120. While the array is shown with 3 baffles in FIGS. 1-2 and 7-8, the array can comprise 2 baffles or more than 3 baffles that are spaced in the particle separator 100. In the embodiments shown in FIGS. 1-2, each baffle 140 a, 140 b, 140 c is a flat rectangular piece of material (see FIG. 6) that is attached along 3 external edges to the inner surface 102 of the particle separator 100. In alternative embodiments, the upstream surface 142 of the baffle may be concave or convex, have an L-shaped cross-section along length L, or have a bend or double bend parallel and adjacent the leading edge 146, whereby the downstream surface 144 or the upstream surface 142 comprises two or more sub-surfaces separated by the bend(s). It is preferred that each baffle is attached in a manner, e.g., welding, sealing, removeably mounted, or the like, that blocks the passage of exhaust between the baffle and the inner surface 102 of the particle separator 100. However, the attachment may not be completely airtight in alternative embodiments.

FIGS. 11a-11b show each baffle 140 a, 140 b, 140 c with a leading edge 146 positioned generally perpendicular to the direction of flow of exhaust entering the particle separator 100. The leading edge 146 has a surface that may be square, rounded or beveled. FIGS. 2b, 10b show the upstream surface 142 positioned at an angle α relative to the inner wall 102 to which it is attached within the particle separator 100, and approximately angle β relative to the linear flow of particle-laden exhaust into the particle separator 100. The angle α can be any angle between about 35-75 degrees, while the angle β can be any angle between about 145-105 degrees. In an embodiment, the angle α is about 40 degrees, while the angle β is about 140 degrees. Each baffle 140 a, 140 b, 140 c may be positioned at angle α and angle β that is the same as or different than the angle α and angle β of other baffle(s).

In embodiments, the angle α is indirectly related to the volumetric flow rate of exhaust flowing through the particle separator 100. For example, the angle α may be lower in cases where the volumetric flow rate is high. Conversely, the angle α may be higher in cases where the volumetric flow rate is low.

FIGS. 2a, 10a show each baffle 140 a, 140 b, 140 c having a length L that positions the leading edge 146 of the baffle within the flow of exhaust entering the particle separator 100. In the embodiments shown in FIGS. 2a, 10a , the leading edge 146 is distance D from inner surface 102 of the particle separator 100, whereby the leading edge 146 may be equidistant from the opposing inner surface 102. The leading edge 146 of each baffle 140 a, 140 b, 140 c can be positioned along a center horizontal axis of the particle separator 100 (see FIGS. 2a, 10a ) of the linear flow of exhaust entering the particle separator 100. In this embodiment, the leading edge 146 on the first baffle 140 a redirects about half of the flow of exhaust, while permitting the other half of the flow of exhaust to pass the leading edge 146 of the first baffle 140 a onward to the second baffle 140 b.

In alternative embodiments shown in FIGS. 11a and 11 c, the leading edge 146 of each baffle 140 a, 140 b, 140 c is positioned at a distance that is greater than distance D from the inner surface 102 on which the edge opposing the leading edge 146 of the baffle is attached. In this configuration, the leading edge 146, which is not equidistant from opposing inner surfaces 102 of the particle separator 100, extends beyond the center of the linear flow of exhaust entering the particle separator 100. The leading edge 146 on the first baffle 140 a redirects more than half of the flow of exhaust, as it enters the particle separator 100, while permitting the rest of the flow of exhaust to pass the leading edge 146 and be redirected by the second baffle 140 b.

In further embodiments, the leading edge 146 of the first baffle 140 a and the second baffle 140 b may or may not be equidistant from the inner surface 102 of the particle separator 100. For example, the leading edge 146 of the first baffle 140 a and the second baffle 140 b are both positioned at distance that is equal to or greater than distance D; the leading edge 146 of the first baffle 140 a is positioned at distance D and the leading edge 146 of the second baffle 140 b is positioned at distance that is greater than distance D; or the leading edge 146 of the first baffle 140 a is positioned at distance D′ and the leading edge 146 of the second baffle 140 b is positioned at distance D as shown specifically in FIGS. 2a , 2 b.

In the aforementioned configurations, the entire flow of particle-laden exhaust entering into the particle separator 100 will be intercepted and redirected by the upstream surfaces 142 of at least the first and second baffles 140 a, 140 b. In an even further embodiment shown in FIG. 12, the first and second baffles 140 a, 140 b may be less than distance D and thereby configured to permit a direct linear flow of a portion of the particle-laden exhaust past the first and second baffles 140 a, 140 b so long as at least a third baffle 140 c is provided at distance D′ to intercept and redirect the entire portion of the particle-laden exhaust that directly and linearly passes the first and second baffles 140 a, 140 b.

In all embodiments, the array of baffles are arranged within the particle separator 100 in a manner that prevents exhaust from flowing directly linearly from the inlet 110 to the outlet 122.

FIGS. 1-2 and 7-8 show a third baffle 140 c linearly spaced downstream from the second baffle 140 b. The third baffle 140 c redirects the flow of exhaust and provides an upstream surface 142 onto which particles can impact and collect downstream from the first and second baffles 140 a, 140 b. Downstream from the second baffle 140 b the flow of exhaust is turbulent, and also non-linear. In further embodiments, additional baffles may be linearly spaced within the particle separator 100. The third baffle 140 c shown in FIGS. 1-2, 7-8, as well as any additional baffle(s), are also attached to the inner surface 102 of the particle separator 100 in the same manner and position as the first and second baffles 140 a, 140 b. Each of these baffles may be spaced such that the leading edge 146 is equal to, greater than or less than distance D from the inner surface 102 on which the edge opposing the leading edge 146 of the baffle is attached.

FIG. 11c shows subchambers A, B, C defined by the baffles within the particle separator 100. The first subchamber A is generally the space within the particle separator 100 that is upstream from the first and second baffles 140 a, 140 b. The second subchamber B of the particle separator 100 is generally the space between the downstream surface 144 of the first baffle 140 a and the upstream surface 142 of the third baffle 140 c. Finally, the third subchamber C is generally the space in the particle separator 100 that is downstream from the downstream surfaces 144 of the second and third baffles 140 a, 140 b. Alternative configurations of the array of baffles will change the number of chambers as would be apparent to one of skill in the art.

FIG. 11a shows an airflow schematic for the exhaust as it is diverted by the baffles 140 a, 140 b, 140 c while passing through the particle separator 100. FIGS. 11a, 11b show the change in the particle density of the exhaust as it contacts the baffles 140 a, 140 b, 140 c while passing through the particle separator 100 and the locations where particles impact the upstream surfaces of the baffles 140 a, 140 b, 140 c and build up. This shows that the density of particles in the exhaust is generally concentrated in the first subchamber A of the particle separator 100. The exhaust from the outlet 120 has a significantly reduced particle content, if any at all. The particle separator 100 reduces the particle content of outlet exhaust by no less than 80% of untreated particle-laden exhaust that is directly blown off from a preconditioner.

Although the initial flow of particle-laden exhaust into the first subchamber A may be entirely diverted by the first and second baffles 140 a, 140 b, the turbulence of airflow in the first subchamber A forces exhaust with a density that is substantially less than that of the initial flow of particle-laden exhaust to circulate outside of the primary flow of exhaust into the first subchamber A and then pass into the second chamber B so that less-dense, particle-laden exhaust is redirected by the third baffle 140 c. This provides conditions for particles to impact the upstream surface 142 of the third baffle 140 c and the inner surface 102 of the particle separator 100 before circulating into the third subchamber C and then out of the outlet 120.

FIG. 1 shows an access door 130 for cleaning the baffles 140 a, 140 b, 140 c and inner surfaces 102 of the particle separator 100. The access door 130 can be attached by a hinge 132 and lock 134 with a handle and includes a seal 136, such as a rubber gasket or high temperature resistant silicon gasket, to create an airtight seal between the door 130 and the particle separator 100 when the door 130 is closed. The door 130 can be opened by rotating the handle and releasing the lock 134 to provide access to the interior of the particle separator 100. This permits the surfaces of the baffles and the inner surfaces 102 of the particle separator 100 to be scraped and/or washed to remove buildup of particles on those surfaces. In certain embodiments, the baffles can be removed for cleaning if configured to do so.

The particle separator 100 is self-cleaning For example, the angle α, optionally combined with a slick coating applied to the upstream and/or downstream surfaces 142, 144, promotes the drainage of moisture and particles from those surfaces during and after operation, even if the upstream surface 142 has a rough surface coating applied to it. The particle separator 100 can also be cleaned by running the steam injectors at a high rate through the preconditioner in the absence of starting ingredients to steam clean the internal surfaces of the particle separator 100.

In a non-limiting embodiment, the particle separator 100 comprises a rectangular box-shaped enclosure defining an enclosed space 104 having an inlet 110 with a tube 112 about 4 inches long and an outlet 120 with a tube 122 about 4 inches long. The tubes 112, 122 are about 8 inches in diameter. The enclosure is about 18 inches tall and about 12-14 inches square across a horizontal cross-section. The bottom of the enclosure is tapered outward from the inlet 110 to the walls of the enclosure. Three baffles are provided whereby the leading edges of the baffles are linearly spaced apart by about 3-4 inches. Each baffle is generally flat and has a dimension that is about 14 inches by 8 inches. The particle separator 100 includes a door 130 that is about 12 inches wide and about 16 inches tall and is used to close an opening into the particle separator that is smaller in dimension than the door. This embodiment of the invention, along with all other embodiments, is configured to engage a vent stack from a preconditioner or other equipment. The length of the vent stack is not critical and can be about 4 feet long in an embodiment.

FIGS. 7-8, 10 a-10 b show an alternative embodiment of the particle separator 100 comprising a tube 200 with baffles 210 a, 210 b, 210 c linearly spaced within the tube 200. The diameter of the tube 200 is not critical as it may be larger or smaller than, or the same as, the diameter of the vent pipe of the preconditioner or other equipment. The tube 200 may be straight or bent at an angle that is no more than 90 degrees. The tube 200 may include at least one taper to increase or decrease the diameter of the tube 200 relative to the diameter of the vent of the preconditioner or other equipment. For example, the tube 200 may have a taper to reduce the diameter of the tube 200 upstream from the baffles. This reduction will cause the exhaust flow to accelerate before reaching the baffles. The tube 200 will have an inlet end 202 that is configured to attach to the vent and an outlet end 204 that is configured to optionally attach to pipe(s) and/or one or more downstream particle separator(s), filter(s), stack(s), water scrubber(s), electrostatic precipitator(s), or other apparatus.

FIGS. 7-9 show that each baffle 210 a, 210 b, 210 c comprises a partial circular edge 212 having an external contour that contacts the inner surface of the tube. The baffle can be adhered or welded to the inner surface 206 or be removeably attached thereto so long as the contact between the partial circular edge 212 and the tube 200 is substantially sealed to prevent flow of exhaust therebetween. Each baffle 210 a, 210 b, 210 c in this alternative configuration would be positioned relative to the tube 200 and inflow of particle-laden exhaust in a similar manner as the configuration for the particle separator 100 shown in FIGS. 1-2. For example, the angle α shown in FIG. 10c can be any angle between about 35-75 degrees, while the angle β can be any angle between about 145-105 degrees. Referring now to FIG. 10b , the length L of the baffles 210 a, 210 b, 210 c and the distance D′ of baffles from the inner surface 206 of the tube 200, including the alternative embodiments thereof, would be similar to those of the particle separator 100 in FIGS. 1-2, which are configured so that the entire flow of particle-laden exhaust entering into the particle separator 100 will be intercepted and redirected by the upstream surfaces 230 and leading edge 232 of the first and second baffles 210 a, 210 b, which block direct linear flow of exhaust from the inlet 202 to the outlet 204.

The particle separator 100 and its components may be made of metal, metal alloys, ceramic, or polymeric material. The choice of material for the particle separator 100 and its components depends on the required material properties or environmental conditions for the intended use of the particle separator 100 that would include consideration of exposure to heat, high moisture, and airflow pressure. Metallic materials, such as stainless steel, are better suited for high temperatures, while polymeric materials may be preferred for cost reasons so long as it would be resistant to thermal loads placed on the particle separator 100.

The particle separator 100 can be used in connection with other commercial and industrial operations that require the removal of particles from a flow of air or gas. Any such use is not limited solely to manage exhaust from a preconditioner for an extruder. For example, the particle separator 100 can be used in connection with any food processing apparatus that injects steam into an operation. The particle separator 100 can be used to scrub particles from any gas stream in an operation. In an application, the particle separator 100 can be positioned in an operation as a pre-cleaner to scrub air or gas flow of particles before the air or gas is introduced to an operation downstream from the particle separator 100. In this operation, the particle separator 100 can scrub a gas flow before the gas is introduced into a combustion chamber, such as in an internal combustion engine or turbine. A person of ordinary skill in the art will appreciate the opportunities for use of the particle separator 100 in different fields of application.

While this subject matter has been disclosed with reference to specific embodiments, it is apparent that other embodiments and variations can be devised by those skilled in the art without departing from the true spirit and scope of the subject matter described herein. The appended claims include all such embodiments and equivalent variations. 

What is claimed is:
 1. A separator for removing particles from a gas flow comprising: an enclosure having an inner surface, an inlet and an outlet, wherein said enclosure is configured to channel a flow of gas having particles commingled therein from said inlet to said outlet; and at least two baffles positioned within said enclosure that are linearly spaced from one another between said inlet and said outlet, wherein each of said baffles provides an upstream surface positioned at an angle that is acute to said inner surface of said enclosure, whereby a combination of each said upstream surface provides a surface area that is greater than an area of a horizontal cross-section of said enclosure.
 2. The separator of claim 1 wherein said horizontal cross-section of said enclosure is round, oval, square or rectangular.
 3. A method for removing particles flowing in a gas stream comprising: channeling a flow of said gas stream through an inlet into a particle separator that obstructs linear flow of said gas stream passing through said particle separator, said particle separator comprising: an outlet, a first inner surface opposing at a distance a second inner surface, and a first baffle that projects at an acute angle from said first inner surface and a second baffle that projects at an acute angle from said second inner surface, whereby said first baffle and said second baffle are spaced from one another between said inlet and said outlet, wherein said first baffle comprises a leading edge that is positioned at a distance from said first inner surface that is equal to or greater than one half of a distance between said first inner surface and said second inner surface, and wherein said second baffle comprises a leading edge that is positioned at a distance from said second inner surface that is equal to or greater than one half of a distance between said first inner surface and said second inner surface, thereby redirecting said flow of said gas stream in a manner that promotes impact of said particles into upstream surfaces of said first baffle and said second baffle, said first inner surface, and said second inner surface before said gas stream exits said outlet with at least 80% of said particles removed therefrom.
 4. The method of claim 3 wherein said first baffle and said second baffle define a first chamber upstream from said first baffle and said second baffle, and a second chamber that is downstream from said first baffle and said second baffle, whereby said first baffle intercepts and redirects a first portion of said gas stream flowing through said inlet into said first inner surface and said second baffle intercepts and redirects a second portion of said gas stream flowing through said inlet into said second inner surface, wherein said first portion and said second portion comprise said gas stream in its entirety flowing through said inlet, and thereafter said gas stream having at least 80% of said particles removed therefrom, passes from said first chamber into said second chamber and out of said particle separator through said outlet.
 5. The method of claim 4 wherein said leading edge of said first baffle is positioned at a distance from said first inner wall and said leading edge of said second baffle is positioned at a distance from said second inner wall that is greater than one half of a distance between said first inner surface and said second inner surface.
 6. The method of claim 4 wherein said leading edge of said first baffle is positioned at a distance from said first inner wall that is greater than one half of a distance between said first inner surface and said second inner surface, and said leading edge of said second baffle is positioned at a distance from said second inner wall that is equal to one half of a distance between said first inner surface and said second inner surface.
 7. The method of claim 4 wherein said leading edge of said first baffle is positioned at a distance from said first inner wall and said leading edge of said second baffle is positioned at a distance from said second inner wall whereby said distance is equal to about one half of a distance between said first inner surface and said second inner surface.
 8. The method of claim 4 wherein said leading edge of said first baffle and said leading edge of said second baffle are spaced from one another at a distance that is less than a diameter or width of said inlet.
 9. The method of claim 4 wherein said leading edge of said first baffle and said leading edge of said second baffle are spaced from one another at a distance that defines an opening having an average cross-sectional area that is about 65% to about 100% of a cross sectional area of said inlet.
 10. The method of claim 3 wherein said particle separator comprises a third baffle, along with said first baffle and said second baffle, that define: a first chamber upstream from said first baffle and said second baffle, a second chamber that is downstream from said first baffle and upstream from said third baffle, and a third chamber that is downstream from said second baffle and said third baffle, whereby said first baffle intercepts and redirects at first portion of said gas stream flowing through said inlet into said first inner surface of said particle separator in said first chamber, said second baffle intercepts and redirects a second portion of said gas stream flowing through said inlet into said second inner surface of said particle separator in said first chamber, and said third baffle intercepts and redirects said gas stream entering said second chamber into said first inner surface of said particle separator in said second chamber, and thereafter said gas stream having a substantial amount of particles removed therefrom, passes from said second chamber into said third chamber and then through said outlet.
 11. The method of claim 10 wherein said leading edge of said first baffle is positioned at a distance from said first inner wall and said leading edge of said second baffle is positioned at a distance from said second inner wall whereby said distance is greater than one half of a distance between said first inner surface and said second inner surface.
 12. The method of claim 9 wherein said leading edge of said first baffle is positioned at a distance from said first inner wall that is greater than one half of a distance between said first inner surface and said second inner surface, and said leading edge of said second baffle is positioned at a distance from said second inner wall at a distance is equal to one half of a distance between said first inner surface and said second inner surface.
 13. The method of claim 9 wherein said leading edge of said first baffle is positioned at a distance from said first inner wall and said leading edge of said second baffle is positioned at a distance from said second inner wall whereby said distance is equal to about one half of a distance between said first inner surface and said second inner surface.
 14. A method for extruding a food product comprising: combining ingredients for said food product in a preconditioner of an extruder; injecting steam into said preconditioner to hydrate said ingredients to form a preconditioned dough in said preconditioner; removing particulate matter from steam exhaust emissions from said preconditioner by: channeling flow of said steam exhaust emissions through an inlet into a particle separator having an outlet; and obstructing said flow of said steam exhaust emissions through said particle separator comprising a first baffle extending away from a first inner surface at an acute angle and a second baffle extending away from a second inner surface at an acute angle, wherein said first baffle and said second baffle are linearly spaced at a distance from one another between said inlet and said outlet so that leading edges of said first baffle and said second baffle define an opening having an average cross-sectional area that is about 65 to about 100% of a cross-sectional area of said inlet, wherein said first baffle comprises a leading edge positioned at a distance that is equal to or greater than one half of a distance between said first inner surface and said second inner surface, and wherein said second baffle comprises a leading edge positioned at a distance that is equal to or greater than one half of a distance between said first inner surface and said second inner surface; thereby redirecting said flow of said steam exhaust emissions in a manner that promotes said particulate matter into contact with said upstream surfaces of said first baffle and said second baffle and said first inner surface and said second inner surface of said particle separator before said steam exhaust emissions exits said outlet having at least about 80% of said particles removed therefrom; and extruding said preconditioned dough using said extruder.
 15. The method of claim 14 wherein said food product comprises pet food, pet treats, animal feed, fish meal, or human food.
 16. An extruder apparatus comprising: a preconditioner having steam or water injection ports and an exhaust opening; a particle separator in communication with said exhaust opening of said preconditioner, said particle separator comprising: an enclosure having a first inner surface spaced at a distance from an opposing second inner surface, an inlet, and an outlet, wherein said enclosure is configured to channel a flow of exhaust emissions from said preconditioner through said inlet to said outlet; and said first baffle extending away from said first inner surface at an acute angle and said second baffle extending away from said second inner surface, wherein said first baffle and said second baffle are spaced from one another between said inlet and said outlet and each provides an impact surface on which particles can deposit, and wherein said first baffle positions a leading edge at distance from said first inner surface that is equal to or greater than one half of a distance measured between said first inner surface and said second inner surface and said second baffle positions a leading edge at a distance from said second inner wall that is equal to or greater than one half of a distance measured between said first inner surface and said second inner surface; and an extruder.
 17. The extruder apparatus of claim 16 wherein said leading edge of each of said first baffle and said second baffle are spaced from one another at a distance that is less than a diameter or width of said inlet.
 18. The extruder apparatus of claim 16 wherein said leading edge of each of said first baffle and said second baffle are spaced from one another at a distance that defines an opening having an average cross sectional area that is about 65 to about 100% of a cross sectional area of said inlet.
 19. A method for extrusion comprising: combining grain-based and/or animal protein-based ingredients for a food product in a preconditioner of an extruder; injecting steam into said preconditioner to hydrate said grain and/or animal protein-based ingredients to form a preconditioned dough; scrubbing exhaust emissions created by injecting steam into said grain and/or animal protein-based ingredients in said preconditioner, wherein said exhaust emissions include particulate matter comprising aerosolized grain-based and/or animal protein-based ingredients, by: directing a linear flow of said exhaust emissions through an inlet into a separator having an outlet; and redirecting said linear flow of said steam exhaust emissions with a first baffle and a second baffle that are linearly spaced from one another between said inlet and said outlet of said separator, wherein said first baffle has an upstream surface at an acute angle relative to a first inner side surface of said particle separator and said second baffle has an upstream surface at an acute angle relative to a second inner side surface of said particle separator, and wherein said first baffle provides a leading edge that is positioned at a distance from said first inner side surface that is equal to or greater than one half of a distance between said first inner side surface and said second inner side surface, and said second baffle provides a leading edge that is positioned at a distance from said second inner side surface that is equal to or greater than one half of a distance between said first inner side surface and said second inner side surface, whereby said flow of said steam exhaust emissions is redirected by said first baffle and said second baffle in a manner that promotes said particulate matter to impact on said upstream surfaces of said first baffle and said second baffle, said first inner surface and said second inner surface before said steam exhaust emissions exits said outlet having at least 80% of said particulate matter removed therefrom; and extruding said preconditioned dough using said extruder.
 21. A device for removing particles from exhaust emissions of an extrusion system comprising: an enclosure comprising an inlet and an outlet on opposing ends of said enclosure and a first inner surface provided at a distance from an opposing second inner surface, wherein said enclosure is configured to channel a flow of exhaust emissions commingled with particles from said inlet through said enclosure to said outlet; a first baffle comprising an upstream surface at an acute angle to said first inner surface of said enclosure and a leading edge positioned at a distance equal to or greater than one half of said distance measured between said first inner surface and said second inner surface; and a second baffle having an upstream surface position at an acute angle to said second inner surface and a leading edge positioned at a distance equal to or greater than one half of said distance measured between said first inner surface and said second inner surface; wherein said leading edge of said first baffle is spaced from said leading edge of said second baffle at a distance that is less than a diameter or width of said inlet thereby defining an opening having an average cross sectional area that is about 65 to about 100% of a cross sectional area of said inlet.
 21. The device of claim 20 wherein said first baffle and said second baffle are sealed along exterior edges to said particle separator to restrict said flow of exhaust emissions between said exterior edges and said particle separator.
 22. The device of claim 20 wherein said acute angle is in a range of about 35-75 degrees.
 23. The device of claim 20 wherein said upstream surfaces of said first baffle and said second baffle is flat, convex, or concave, or have a cross section that can be L-shaped.
 24. The device of claim 20 wherein said leading edge has a surface that is flat, rounded or beveled.
 25. The device of claim 20 wherein said leading edge is linear, curvilinear, notched, or any combination thereof.
 26. The device of claim 20 wherein downstream surfaces of said first baffle and said second baffle are coated with a rough coating or a slick coating.
 27. The device of claim 20 comprising a third baffle spaced downstream from said first baffle and said second baffle.
 28. The device of claim 20 wherein a combination of each of said upstream surfaces provides a surface area that is greater than an area of a horizontal cross-section of said enclosure.
 29. A device for separating particles from exhaust emissions of an extrusion system comprising: a tube having an inner surface configured to channel a flow of exhaust emissions commingled with particles therein from an inlet to an outlet of said tube; a first baffle attached at an acute angle to said inner surface, said first baffle comprising an upstream surface and a leading edge that is positioned perpendicular to said inner surface and said leading edge having a center portion positioned at a distance equal to or greater that one half of a diameter of said tube; a second baffle attached at an acute angle to said inner surface, said second baffle comprising an upstream surface and a leading edge that is positioned perpendicular to said inner surface and said leading edge having a center portion positioned at a distance equal to or greater that one half of a diameter of said tube; wherein said leading edge of said first baffle is positioned at a distance from said leading edge of said second baffle that is less than a diameter of said inlet, thereby defining an opening having an average cross sectional area that is about 65 to about 100% of a cross sectional area of said inlet. 